DIFFERENTIAL CASE REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL CASE


    1. Coat the contact surfaces of the front differential side gears with gear oil.

    2. A01VGA7

      Install the 2 front differential side gear thrust washers to the 2 front differential side gears.

    3. Coat the contact surfaces of the front differential pinions with gear oil.

    4. A01VJMX

      Install the 2 front differential side gears, 2 front differential pinions and 2 front differential pinion thrust washers to the front differential case.

      Tech Tips

      While rotating the front differential side gears, install the 2 front differential pinions and 2 front differential pinion thrust washers.

    5. Coat the front No. 1 differential pinion shaft with MP grease.

    6. A01VJPI

      Install the front No. 1 differential pinion shaft to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.

  2. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH

    Click here

  3. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


    1. A01VGMR

      Using a pin punch and hammer, tap in the front differential pinion shaft straight pin to the front differential case.

    2. A01VGI8

      Using a hammer and chisel, stake the pin holes around the circumference of the front differential case.

  4. INSTALL FRONT DIFFERENTIAL RING GEAR


    1. Clean the contact surfaces of the front differential case and ring gear.

    2. A01VGFR

      Using a heater, heat the front differential ring gear to 90 to 110°C (194 to 230°F).

    3. A01VGMUE09
      Text in Illustration
      *a Matchmark

      After the moisture on the front differential ring gear has completely evaporated, quickly align the matchmarks on the front differential ring gear and front differential case and install the front differential ring gear to the front differential case.

    4. Install the new 6 bolts.

      Torque:
      124 N*m  { 1260 kgf*cm, 91 ft.*lbf }

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01VIPPE04

      Using SST and a press, install the front differential case rear tapered roller bearing to the front differential case.

      SST
      09350-32014   ( 09351-32120, 09351-32140 )

  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01VGKHE02

      Using SST and a press, install front differential case front tapered roller bearing to the front differential case.

      SST
      09350-32014   ( 09351-32120, 09351-32140 )